<p>A new analysis method was introduced to predict the densification behavior of casting ingots with pore defects through large plastic deformation. Round billets with axial pore defects were transformed to be a heterogeneous model using 3D mapping algorithm, which enabled the analysis of the densification behavior of the porous regions along the central axis based on the yield criterion of porous materials. The results showed that higher effective strain and hydrostatic stress were generated in the central axial porous region of defective billets compared to non-defective ones, promoting densification in these regions. However, the densification behavior was poor for the porous regions near the anvils due to weak effective strain and compression stress in those areas. Building on this, the influence of the friction coefficient and reduction ratio on the densification behavior of the axial porous region of the round billets was further studied. This analysis method incorporates the actual distribution of pore defects in casting ingots into the quality analysis of forgings, significantly improving the reliability of process control in forging.</p>